Image Forming Apparatus Capable of Determining Whether Enough Ink Remains

This application claims priority to Japanese Patent Application No. 2024-070073 filed on Apr. 23, 2024, the entire contents of which are incorporated by reference herein.

The present disclosure relates to image forming apparatuses and particularly relates to a technique for ordering a recording agent container containing a recording agent, such as ink or toner.

In an image forming apparatus loaded with a recording agent container (for example, an ink container) containing a recording agent, such as ink or toner, printing cannot be done when the recording agent container becomes empty. Therefore, some image forming apparatuses have the function of automatically ordering a new recording agent container when a near-end condition has occurred where the recording agent in the recording agent container is running out. Furthermore, there is also proposed a technique for detecting a near-end condition of toner.

A technique improved over the aforementioned techniques is proposed as one aspect of the present disclosure.

An image forming apparatus according to an aspect of the present disclosure includes an image forming device, a plurality of container loaders, and a control device. The image forming device forms an image on a recording medium using a recording agent. The control device includes a processor and functions, through the processor executing a control program, as a remaining amount detector and a remaining amount condition determiner. The plurality of container loaders are capable of removably loading respective recording agent containers each containing a recording agent of the same color. The remaining amount detector detects a remaining amount of recording agent in each of the recording agent containers loaded in the container loaders. The remaining amount condition determiner determines, based on the remaining amount of recording agent in each of the recording agent containers detected by the remaining amount detector, whether or not a remaining amount alert condition has occurred in which the remaining amount of recording agent in one of the recording agent containers loaded in the container loaders or a total remaining amount of recording agent of the same color has reduced to a predetermined lower limit.

Hereinafter, a description will be given of an image forming apparatus according to an embodiment of the present disclosure with reference to the drawings.is a partial cross-sectional front view showing the structure of an image formation system made up by including an image forming apparatus according to one embodiment of the present disclosure.

An image formation systemincludes an image forming apparatusand a post-processing deviceconnected to the image forming apparatus. The image forming apparatusis, for example, a multifunction peripheral having a plurality of functions, including a copy function and a print function, and forms an image on a recording paper sheet as a recording medium using ink as a recording agent in an ink-jet system. The image forming apparatusincludes: a main apparatusthat forms an image on a recording paper sheet; and a sub apparatuswhich is loaded with ink containers(ink containersA toH in) containing ink and supplies the ink in the ink containersto the main apparatus. The ink containeris an example of the recording agent container defined in CLAIMS.

is a front view schematically showing the structure of the sub apparatusincluded in the image forming apparatus. The image forming apparatusis capable of loading a plurality of (two in this embodiment) ink containers containing ink of the same color. As shown in, the sub apparatusincludes container loadersA toH capable of removably loading respective ink containersA toH each shown by a rectangle of broken-lines. The container loadersA,B load respective ink containersA,B containing black ink, the container loadersC,D load respective ink containersC,D containing cyan ink, the container loadersE,F load respective ink containersE,F containing magenta ink, and the container loadersG,H load respective ink containersG,H containing yellow ink.

The container loadersA toH are provided with respective container coversA toH that open and close respective loading openings in the container loadersA toH. The ink containersA toH, the container loadersA toH, and the container coversA toH are also referred to collectively as the ink containers, the container loaders, and the container covers, respectively.

is a functional block diagram schematically showing an essential internal configuration of the image forming apparatus. The image forming apparatusincludes a control device, a document feed device, a document reading device, an image forming device, container loaders, ink containers, a sheet feed device, an ink supply mechanism, an operation device, a communication device, and a storage device.

The document feed deviceis capable of being opened and closed with respect to the top surface of the document reading deviceby being mounted by unshown hinges or the like on the top surface of the document reading device, and functions as a document holding cover while the document reading devicereads an original document sheet placed on an unshown platen glass. Furthermore, the document feed deviceis an ADF (auto document feeder), includes an unshown document loading tray, and feeds original document sheets loaded onto the document loading tray to the document reading devicesheet by sheet.

The document reading deviceincludes a scanner or the like and reads, with the scanner or the like, an original document sheet fed from the document feed deviceor an original document sheet placed on the platen glass. Furthermore, the document reading devicecan sequentially read images of a plurality of original document sheets fed from the document feed device.

First, a description will be given of the case where a document reading operation is performed on the image forming apparatus. The document reading deviceoptically reads an image of an original document sheet fed to the document reading deviceby the document feed deviceor an image of an original document sheet placed on the platen glass and generates image data on the original document sheet. The image data generated by the document reading deviceis saved in an unshown image memory or the like. Next, a description will be given of the case where an image forming operation is performed on the image forming apparatus. The image forming deviceincludes: respective ink heads that discharge ink drops of different colors (black, cyan, magenta, and yellow); a print conveyance unit, and a dry conveyance unit. Based on image data generated by the document reading operation, image data stored in the image memory or the like, image data received from a computer connected via a network or another image data, the image forming deviceforms an image on a recording paper sheet as a recording medium fed from the sheet feed device, using ink contained in the ink containersloaded in the container loadersin an ink-jet system.

The print conveyance unit includes an endless conveying belt and conveys a recording paper sheet using the conveying belt while facing the ink heads. The dry conveyance unit includes an endless conveying belt, like the print conveyance unit, conveys a recording paper sheet with an image formed thereon, using the conveying belt, and naturally dries the ink adhering to the recording paper sheet while conveying the recording paper sheet.

The recording paper sheet with an image formed thereon by the image forming deviceis conveyed via the sub apparatus(see) to the post-processing device(see), in which, if necessary, the recording paper sheet is subjected to post-processing, such as stapling.

The sheet feed deviceincludes a plurality of sheet feed cassettes and further includes respective pick-up rollers each of which picks up a recording paper sheet from the associated sheet feed cassette and feeds it to the image forming device, a conveyance roller, a conveyance path, and a rotation drive mechanism for the rollers.

Each of the container loadersis provided with a container cover, a cover open/close sensor, a container sensor, an empty sensor, and an RFID (radio frequency identification) reader/writer. The cover open/close sensordetects an open or closed state of the container coverand is, for example, a limit switch that is turned ON/OFF according to the opening/closing of the container cover.

The container sensordetects the presence or absence of an ink containerloaded in the container loaderand is, for example, a limit switch that is turned ON/OFF according to the attachment/removal of an ink container. The empty sensoris a sensor that detects the presence or absence (i.e., an empty state) of ink in the ink containerloaded in the container loaderand is, for example, an optical sensor.

The RFID reader/writerreads data from and writes data to an RFID tag (not shown) attached to the ink containerloaded in the container loader. The data to be written to the RFID tag includes a unique product serial number, color information, information on the expiration date, and, at the factory, a default value of an ink capacity of the ink container as information on the remaining ink amount.

A controllerto be described hereinafter reads the information on the remaining ink amount recorded on the RFID tag, for example, through the RFID reader/writer. Thus, the image forming apparatus(the controller) can recognize the remaining amount of ink in the ink container. Furthermore, when ink is used (such as during printing or maintenance), the controllerdetects the amount of ink consumed (for example, calculates the amount of ink consumed by counting the number of discharges of ink liquid from the ink head), calculates the remaining amount of ink in the ink containerfrom the detected amount of ink consumed, and timely writes through the RFID reader/writerinformation on the calculated remaining amount of ink to the RFID tag to update the information on the remaining ink amount stored in the RFID tag. The controlleris an example of the remaining amount detector defined in CLAIMS.

When the ink containeris a regular product (a so-called genuine ink container produced as available for use in the image forming apparatus), the RFID reader/writerperforms appropriate wireless communications with the RFID tag. However, when the ink containeris not a regular product (is a non-genuine product), no RFID tag capable of communications with the RFID reader/writermay be attached thereto. In this case, the

RFID reader/writermay not be able to perform appropriate wireless communications with the ink container(the RFID tag) and thus may not be able to acquire information on the remaining ink amount in the ink container. Whether or not the ink containeris a regular product is determined by the controllerfrom the product serial number or the like written on the RFID tag. For example, when the controllerreads a product serial number from the RFID tag on the ink containerwith the RFID reader/writer, the controllerdetermines that the ink containeris a regular product. On the other hand, when the controllercannot read a product serial number from the RFID tag on the ink container, it determines that the ink containeris a non-regular product. In addition, the controllerdetermines the expiration date of the ink containerfrom the information on the expiration date read from the RFID tag on the ink containerby the RFID reader/writer.

The ink supply mechanismsupplies ink in the ink containersloaded in the container loadersto the image forming deviceand includes, for example, a syringe pump, a plurality of pipes, a plurality of valves, and a plurality of coil springs, wherein the syringe pump is connected through the pipes to ink supply ports of the ink containersand connected through the pipes to the image forming device. The ink supply port is opened and closed by the valve and the valve is biased by the coil spring.

The operation deviceincludes various types of hard keys to be operated by the user and accepts, according to user's operation on the hard keys, user's instructions for various types of operations and processing executable by the image forming apparatus, such as an instruction to execute an image forming operation.

The operation deviceincludes a display devicethat displays operation guidance and other types of information for the operator. Furthermore, the operation deviceaccepts, through a touch panel provided on the display device, input of a user's instruction based on an operation (a touch gesture) of the user on the screen being displayed on the display device.

The display deviceis formed of a liquid crystal display (LCD) or the like. When the operator makes a touch gesture on a button or key being displayed on the screen, the touch panel accepts an instruction associated with a point where the touch gesture has been made. In this case, the touch panel functions as an operation device.

The communication deviceis a communication interface that sends and receives various types of data to and from external devices (for example, personal computers and a server) in a local area network or on the Internet.

The storage deviceis a large storage device, such as an HDD (hard disk drive) or an SSD (solid state drive), and stores various control programs and others.

The control deviceis made up by including a processor, a RAM (random access memory), a ROM (read only memory), and a dedicated hardware circuit. The processor is, for example, a CPU (central processing unit), an ASIC (application specific integrated circuit) or an MPU (micro processing unit). The control deviceincludes the controller, a total remaining amount calculator, and a remaining amount condition determiner.

When the processor operates in accordance with a control program stored in the storage device, the control devicefunctions as the controller, the total remaining amount calculator, and the remaining amount condition determiner. However, each of the controller, the total remaining amount calculator, and the remaining amount condition determinermay not be implemented by the operation of the control devicein accordance with the control program but may be constituted by a hardware circuit. Hereinafter, the same applies to the other embodiments unless otherwise stated.

The controllergoverns the overall operation control of the image forming apparatus. The controlleris connected to the document feed device, the document reading device, the image forming device, the container loaders, the ink containers, the sheet feed device, the ink supply mechanism, the operation device, the communication device, and the storage deviceand controls the operations of these components to execute various types of processing necessary for image formation of the image forming apparatus. For example, the controllercontrols the operation of the image forming deviceto allow the image forming deviceto perform printing. In doing so, regarding the plurality of ink containerscontaining ink of the same color, the controllerpreferentially uses, for printing, an ink container closer to the expiration date or an ink container having a smaller remaining amount of ink.

The total remaining amount calculatorcalculates, based on the respective remaining amounts R of ink in the ink containersloaded in the container loaders, the total remaining amount TR of ink of the same color (ink contained in respective ink containersloaded in container loadersconfigured to load a plurality of (two in this embodiment) ink containerscontaining ink of the same color). For example, the total remaining amount TR of black ink is determined by summing the respective remaining amounts R of ink in the ink containerA and the ink containerB.

The remaining amount condition determinerdetermines whether or not a remaining amount alert condition has occurred in which the remaining amount R of ink in an individual one of the ink containersloaded in the container loadersor the total remaining amount TR of ink of the same color has reduced to a predetermined lower limit L. Specific examples of the manner of determination made by the remaining amount condition determinerwill be described below in two determination manners. The lower limit L may be settable by the user. In this case, based on the lower limit L from user setting accepted by the operation device, the remaining amount condition determinerdetermines whether or not a remaining amount alert condition has occurred.

In <<Determination Manner 1>>, whether or not a remaining amount alert condition has occurred is determined using the total remaining amount TR of ink of the same color. In <<Determination Manner 2>>, whether or not a remaining amount alert condition has occurred is determined using the remaining amount R of ink in an individual one of the ink containers.

<<Determination Manner 1>>When black ink in the ink containerA is used, the controllerdetects the amount of the ink consumed and calculates the remaining amount R of ink in the ink containerA from the amount of the ink consumed.

The total remaining amount calculatorsums the remaining amount R of ink in the ink containerA and the remaining amount R of ink in the ink containerB containing black ink separately from the ink containerA to calculate the total remaining amount TR of black ink. Information indicating the respective remaining amounts R of ink in the ink containerA before use and the ink containerB before use is recorded on the respective RFID tags. Therefore, the total remaining amount calculatorreads from the RFID tags the respective remaining amounts R of ink in the ink containersA,B before use.

The remaining amount condition determinercalculates the rate RTof the total remaining amount TR of black ink to the total capacity (the sum of the default values of the capacities of the ink containersA,B) and determines whether or not the calculated rate RThas reduced to the lower limit L (for example, 10%), thus determining whether or not a remaining amount alert condition has occurred. The lower limit L is not limited to a relative value indicated by the above rate, but may be an absolute value consisting of a predetermined amount of ink.

When a non-regular ink containeris loaded in a container loader(when an ink containerloaded in a container loaderis determined to be a non-regular ink container by the controller), the remaining amount condition determinerdoes not determine, as for ink of the same color as the ink contained in the ink container, whether or not a remaining amount alert condition has occurred. The reason for this is that correct information on the remaining ink amount may not be able to be obtained from the non-regular ink container.

<<Determination Manner 2>> When ink in the ink containerA is used, the controllerdetects the amount of the ink consumed and calculates the remaining amount R of ink in the ink containerfrom the amount of the ink consumed.

The remaining amount condition determinercalculates the rate RTof the remaining amount R of ink in the ink containerto the capacity (the default value of the capacity of the ink containerA) and determines whether or not the calculated rate RThas reduced to the lower limit L (for example, 10%), thus determining whether or not a remaining amount alert condition has occurred.

As for the container loadernot loading an ink container, the remaining amount condition determinerdoes not determine whether or not a remaining amount alert condition has occurred. Furthermore, also as for the ink in a non-regular ink container, the remaining amount condition determinerdoes not determine whether or not a remaining amount alert condition has occurred. As described previously, the reason for this is that correct information on the remaining ink amount may not be able to be obtained from the non-regular ink container.

When the remaining amount condition determinerdetermines that a remaining amount alert condition has occurred, the controllerexecutes predetermined order processing for ordering an ink containercontaining ink of the same color as the ink as for which a remaining amount alert condition has occurred.

As the above order processing, for example, the controllersends information for ordering the ink containerthrough the communication deviceto a server managed by an office for ink container delivery service. Alternatively, as the above order processing, the controllercontrols the display of the display deviceto allow the display deviceto display information indicating that the ink containerneeds to be ordered.

Next, a description will be given of an example of a form of processing for ordering an ink containeron the image forming apparatuswith reference to the flowchart shown in. This processing is processing executed when ink contained in an ink containeris used (such as during printing or during maintenance). The following description is given of the case where the above <<Determination Manner 1>> is used, taking as an example the case where black ink contained in the ink containerA is used.

When ink contained in the ink containerA begins to be used, the controllerdetermines whether or not at least one of the ink containersA,B containing black ink is a non-regular product (S).

When determining that both the ink containersA,B are not non-regular products (are regular products) (NO in S), the controllerdetects the amount of ink consumed in the ink containerA (S) and calculates the respective remaining amounts R of ink in the ink containersA,B based on the detected amount of ink consumed (S), and the total remaining amount calculatorsums the respective remaining amounts R of ink in the ink containersA,B to calculate the total remaining amount TR of the ink (S).

When there is any container loadernot loading an ink container, the total remaining amount calculatorcalculates the total remaining amount TR by assuming the remaining amount of ink in an ink container assumed to be loaded in the ink container-free container loaderto be zero.

The remaining amount condition determinercalculates the rate RTof the total remaining amount TR of black ink to the total capacity (the sum of the default values of the capacities of the ink containersA,B) (S) and determines whether or not the calculated rate RThas reduced to the lower limit L (for example, 10%) (S).

When the remaining amount condition determinerdetermines that the rate RThas not reduced to the lower limit L (NO in S), the processing goes back to S.

On the other hand, when the remaining amount condition determinerdetermines that the rate RThas reduced to the lower limit L (YES in S), the controllerexecutes order processing for ordering an ink containercontaining black ink (S). For example, when the lower limit Lis set to about%, both the ink containers are close to be empty and, therefore, the controllerexecutes order processing for ordering two ink containersfor black ink. When the lower limit L is set to about 50%, one of the ink containers is highly likely to still contain enough ink and, therefore, the controllerexecutes order processing for ordering a single ink containerfor black ink.